KUKA KR C5 Controller Assembly and Troubleshooting

After replacing the system board battery, plug in the USB keyboard, enter the BIOS to set the date and time, load the default values, and perform a functional test. After replacing the SSD, check the settings and perform a functional test. After replacing IFBsafe or IFBsafext, check whether the CSP LED is lit and whether the startup is normal. When replacing the internal SSD, one M3x2.5 cross screw needs to be unscrewed. When replacing the connection board, the system board should be removed first, and then the connection board should be pulled out vertically. Be careful not to tilt it during installation. When replacing KSP-STA, it is necessary to remove 5 M3x8 TORX screws and pay attention to the vertical connection plate.

Common troubleshooting: Starting with KSP alarm and CSP LED

KSP warning messages are the focus of investigation. 26103 internal error: reinitialize the driver bus, Power Off/On。 26104 IxT overload: When starting, the program load is too high. During operation, check the mechanical, temperature, and current trajectories, reduce the program speed, and check the CBS pressure and gearbox. 26105 Grounding Fault: Check the motor cable and motor. 26106 Overcurrent: Check the current trajectory, motor, and motor cable. 26107 Intermediate circuit overvoltage: Check the trajectory of the intermediate circuit, main power supply, and braking resistor to reduce the braking load. 26108 Intermediate circuit undervoltage: Check the trajectory of the intermediate circuit and the main power supply. 26112 radiator overheating: Check the fan, ambient temperature, program load, cooling circuit cleanliness, installation position, and ventilation gap. 26113 motor phase loss: Check the motor cable and motor. 26114 communication error: reinitialize the driver bus, check the EtherCAT cable and stack. 26118 Power phase loss: Check the power cord. 26119 power failure: Check the power cord and fuse. 26122 brake resistor fault: Check the brake resistor. 26123 Braking resistor overload: Reduce frequent braking overload and check the braking resistor. 26131 Intermediate circuit charging failure: Check the intermediate circuit cable, main power supply, and system impedance. 26133 brake fault: Check the motor/brake, brake cable/motor cable.

CSP LED is also an important clue. LED1 white indicates operating mode, LED2 green indicates operating status, LED3 red indicates error, and LED4 white indicates sleep/soft power. All off indicates that the controller is turned off; Irregular flashing of LED4 indicates sleep mode; LED4 flashing slowly indicates Bus Power Off. When LED1 to LED4 are all on during startup, it indicates LED testing, and then turning off indicates that BIOS POST is still running; LED2 slow flashing indicates that BIOS is OK and startup has started; LED2 lights up to indicate startup completion. When running, LED2 lights up to indicate T1/T2, and LED1 and LED2 lights up to indicate automatic mode. LED3 flash indicates PROFINET ping, slow flash indicates maintenance mode.

Regarding startup errors: LED2 flashing and LED3 lit up indicate a BIOS error. You can replace the SSD or check the USB; If LED2 flashes slowly and LED3 lights up, it indicates that PMS startup has timed out and the mirror needs to be reloaded; LED2 and LED3 flash rapidly, indicating a software startup error and the need to reload the image; During operation, both LED2 and LED3 are lit, indicating a fatal error. Please check the smartPAD error message. The recovery image can be created or restored using KUKA. Recovery USB V4 or higher, in conjunction with Windows 10 64 bit PC, following the CSP status prompt to create or restore C and D drive images. If the system board LED lights up red, turn off the controller, unplug the power cord, and contact KUKA customer service.